Entropy 2015, 17, 3438-3457; doi:10.

3390/e17053438
OPEN ACCESS

entropy
ISSN 1099-4300
www.mdpi.com/journal/entropy
Article

Heat Transfer and Pressure Drop Characteristics in Straight

Microchannel of Printed Circuit Heat Exchangers
Jang-Won Seo 1, Yoon-Ho Kim 2, Dongseon Kim 3, Young-Don Choi 1,* and Kyu-Jung Lee 1
1

Department of Mechanical Engineering, Korea University, Seoul 136-713, Korea;

E-Mails: versatile@korea.ac.kr (J.-W.S.); kjlee@korea.ac.kr (K.-J.L.)
Samsung Electronics Co., Ltd., Maetan 3-dong, Yeongtong-gu, Suwon 443-742, Korea;
E-Mail; yoonhk@korea.ac.kr
Department of Mechanical Engineering, Korea National University of Transportation,
Chungbuk 380-702, Korea; E-Mail: dongseonkim@ut.ac.kr

* Author to whom correspondence should be addressed; E-Mail: ydchoi@korea.ac.kr;

Tel.: +82-2-3290-3355; Fax: +82-2-928-1607.
Academic Editor: Kevin H. Knuth
Received: 11 January 2015 / Accepted: 13 May 2015 / Published: 18 May 2015

Abstract: Performance tests were carried out for a microchannel printed circuit heat
exchanger (PCHE), which was fabricated with micro photo-etching and diffusion bonding
technologies. The microchannel PCHE was tested for Reynolds numbers in the range of
100850 varying the hot-side inlet temperature between 40 C50 C while keeping the
cold-side temperature fixed at 20 C. It was found that the average heat transfer rate and
heat transfer performance of the countercurrrent configuration were 6.8% and 10%15%
higher, respectively, than those of the parallel flow. The average heat transfer rate, heat
transfer performance and pressure drop increased with increasing Reynolds number in all
experiments. Increasing inlet temperature did not affect the heat transfer performance
while it slightly decreased the pressure drop in the experimental range considered.
Empirical correlations have been developed for the heat transfer coefficient and pressure
drop factor as functions of the Reynolds number.
Keywords: microchannel; printed circuit heat exchanger (PCHE); micro photo-etching;
diffusion bonding; counterflow

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1. Introduction
A printed circuit heat exchanger (PCHE) is fabricated by diffusion-bonding thin metal plates which
were previously engraved with flow channels using chemical erosion techniques. As illustrated in
Figure 1, the PCHE appears solid and seamless as the diffusion-bonding technique promotes growth of
crystal grains between metallic surfaces that are compressed at a high temperature below the melting
point [1], allowing for light weight and high structural strength. The micro photo-etching technique
which has been developed with the progress of MEMS technologyenables the processing of
sophisticated microchannels on the metal surface. Additionally, development in the MEMS field has
also allowed for easy mass production, reliability and economic efficiency [2,3].

Figure 1. Flow cross-section of a printed circuit heat exchanger (PCHE) fabricated using
diffusion bonding [1].
Generally, for a conventional heat exchanger, the brazing techniquewhere bonding occurs
by melting a binderis widely used. A microchannel PCHE created through diffusion bonding has
superior heat resistance and bonding strength than one created by the brazing technique. Because there
is almost no thermal resistance, nor reduction or clogging of the microchannels at the time of bonding,
excellent production properties and thermal performance can be achieved. Because of these advantages,
it is possible to use this microchannel PCHEcreated through diffusion bondingin various fields
such as fuel cell systems, chemical reaction processes, marine and terrestrial plants, and refrigeration
and air conditioning systems, and the potential fields of use continue to expand [4,5].
Among the previous studies on micro heat exchangers, Peng et al. [6] conducted a study on the
effect of the convection heat transfer coefficient on laminar and turbulent flows by using a rectangular
microchannel. They determined that the degree of influence on the convective heat transfer coefficient
is different, but the hydraulic diameter of each channel, and the gap between aspect ratio and channel
under laminar and turbulence flow are important factors. Lee et al. [7] studied the local convective
heat transfer characteristics of the rectangular microchannel through a numerical analysis. They found
that as the Reynolds number is increased, the heat transfer performance was improved. Also, through
comparison of numerical analysis and experimental results, Qu et al. [8] concluded that there is no
difference in the macro-sized channel heat exchanger in terms of the flow in the rectangular
microchannel. Shen et al. [9] conducted a study on Poiseuille number, local Nusselt number and the
surface roughness in a rectangular microchannel. They reported that the friction factor in the
microchannel of laminar flow was measured larger than predicted, and the local and average Nusselt
number was smaller than the predicted value. In addition, they suggested experimental correlations as
functions of the Reynolds number for friction factor and the Nusselt number. Rachkovskij et al. [10]

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conducted a study on a cross-flow heat exchanger with laminated layers of 20 sheets and the aspect
ratio of the microchannel, and in this experiment, air-air was used as the working fluid. From their
research results, they suggested an optimal temperature proximity and volume heat transfer coefficient.
Kang et al. [11] suggested a theoretical model which can be used to predict the heat and fluid
properties of a micro-cross-flow heat exchanger. Nikitin et al. [5] experimentally investigated the heat
transfer and pressure drop characteristics of supercritical CO2. They also proposed empirical
correlations for the local heat transfer coefficient and the pressure drop factor as functions of the
Reynolds number. Ngo et al. [12] have manufactured a new PCHE with an s-shaped pin by improving
Nikitin et al.s [5] straight channel PCHE and conducted experiments on this new PCHE. In addition,
they evaluated the thermal hydraulic performance through a numerical analysis. Tsuzuki et al. [13]
performed a numerical analysis for s-shaped and various zigzag-shaped PCHEs. They evaluated the
thermal hydraulic performance by calculating the heat transfer and pressure drop. Ma et al. [14]
performed a numerical analysis for the offset bubble and the offset-strip fin configurations. In this study,
a cross-flow pattern was employed for the offset-bubble configuration pattern while the offset-strip fins
flow direction involved dispersion of the working fluid. Ma et al.s [14] numerical analysis model
focused on one region of the repeated small channels, using symmetric and periodic boundary
conditions. The numerical analysis method assumed an incompressible fluid and used a governing
equation while using Nusselt number and friction factor to analyze and compare results for both
configurations. Ma et al. [15] manufactured a PCHEthrough a photo-chemical etching methodwith
thermal plates of an airfoil channel configuration. This PCHE was then analyzed using a numerical
analysis method, followed by a grid test which corresponded with experimental data. In order to
analyze the effect of the fin-endwall fillet, Ma et al. [15] then varied the pitch of the airfoil fins and
analyzed the Nusselt number and friction factor results. Ma et al [16] performed a numerical analysis
for a PCHE with a zigzag channel configuration. The pitch, length, and angle of the zigzag channels
were varied and heat transfer characteristics for a laminar flow region of a Reynolds number range of
4002000 were studied. This numerical analysis assumed a working fluid of air and helium with an
inlet temperature of 900 C. The numerical method results were analyzed using Nusselt number,
Colburn j-factor and Fanning friction factor (f-factor). Baek et al. [17] investigated flow maldistribution
and axial conduction in regards to PCHE header configuration. Using a numerical analysis method, the
flow direction of the working fluid for both vertical and horizontal configurations was considered.
Through the NTU method, the effectiveness was obtained and a Nusselt number correlation for
microchannels was proposed. Bartel et al. [18] studied PCHEs within advanced nuclear reactors.
Within these PCHEs, wavy channel and offset strip fin configurations were compared and analyzed.
Furthermore, a Colburn j-factor and fanning friction factor (f-factor) was proposed. Figley et al. [19]
researched PCHEs utilized in reactors with high-temperature regions. Using a flow analysis
programFluent Softwarenumerical results were acquired. Correlation of the pressure drop
results was compared with the numerical analysis, allowing for the validity to be confirmed.
Through comparison of the mass flow rate and NTU, the performance effectiveness was calculated.
Kim et al. [20], after manufacturing a PCHE heat transfer plate and creating a 3D model of this plate,
performed a numerical analysis. By changing the geometric parameters of the fin arrangement, the
pressure drop and heat transfer characteristics were investigated in regards to geometric properties.
Through these heat transfer characteristics results, the Colburn j-factor, Nusselt number and Euler

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number were expressed. Kim et al. [20] also compared the Fanning friction factor in accordance with
Reynolds number. Koo et al. [21] investigated the flow characteristics of a PCHE inlet through a 3-D
Reynolds-averaged Navier-Stokes analysis. Two other surrogate modelsthe Krigin and radial basis
neural networks were also employed. Additionally, in accordance to the flow rate increase and
channel number, the flow characteristics were compared and analyzed. Mylavarapu et al. [22]
conducted a numerical analysis based on a model of a PCHE for high-temperature gas-cooled reactors.
Using a Reynolds number region of less than 2300, existing formulas were compared with the
proposed correlation and analyzed, with the results of the cold and hot sides considered independently
of each other. According to the Reynolds number, the Fanning friction number and Nusselt numbers
were calculated, and experimental data was compared with the circular pipe correlation. Xu et al. [23]
conducted a study on the optimization of fin arrangement and channel configuration for PCHEs using
supercritical CO2 as a working fluid. The fin dimensions were varied, involving an airfoil fin type and
differing fin thickness, length, and width. The average Nusselt number and pressure drop results were
analyzed, in accordance to the increasing Reynolds number. Yoon et al. [24] analyzed four PCHE
configurations; straight, zigzag, s-shape and airfoil channel. A numerical analysis method was used,
employing a 3D model of the minimum unit structure which removed the need for numerical
construction of the entire PCHE. This allowed for the hydraulic diameter, Nusselt number and pressure
drop to be compared. The two working fluids used were helium and CO2, with the Fanning for each of
the two working fluids calculated and compared. In addition, as part of a cost analysis, the total cost of
each of the three different channel configurations was calculated. Yoon et al. [25] conducted a study
focusing on crossflow PCHEs within advanced small modular reactors. After confirming a design
model, the MATLAB program was used to analyze through mathematical methods. First, a single-pass
crossflow was designed and then partial differential equations were obtained by employing the Laplace
transform and inverse transform. This allowed for solutions for each variable to be obtained. Yoon et al.
[25] then calculated results for the thermal design process, cost estimation methodology, effectiveness
and crossflow PCHE analysis. Jeong et al. [26] proposed enhancements to the plate fin type heat
exchanger after modelling a fin type and louver fin heat exchanger configuration. Subsequently, in
order to evaluate the grid reliability, friction factor and convergence grid tests were performed. The
effective area factor was determined through calculation of the non-dimensional factor, Colburn
j-factor, and Fanning friction factor (f-factor), and this performance of the commercial-fin
configuration was compared with the proposed enhanced fin configuration. Kim et al. [2729]
conducted a numerical analysis for PCHEs with wavy channels of variable angles and with a hot-side
double-banking heat plate arrangement. Kim et al. [2729] proposed a heat transfer and pressure drop
correlation for a working fluid of helium and a Reynolds number of 3000 or lower. Furthermore,
Kim et al. [2729] considered the cost of the system power loss, in regards to the stacked thermal plate
layers, and analyzed the results to propose an improved PCHE design method.
Aside from these previous studies, research on PCHEs is rather limited, especially when
considering the significant amount of research that has been conducted on other types of commercial
heat exchangers. Furthermore, within the body of heat exchanger research there are few studies
examining microfluidics and pressure drop characteristics and with most employing a Reynolds
number less than 1000 in conjunction with an average and unchanging Nusselt number.

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In this study, the authors have fabricated PCHE heat exchangers with straight-tube-shaped
microchannels and obtained heat transfer and pressure drop data by varying the Reynolds number and
the operating temperature. From the results, empirical correlations have been proposed for the heat
transfer coefficient and friction factor, which can be used as the basic data for heat exchanger design.
2. Experimental Setup and Data
2.1. Microchannel PCHE
The microchannels were formed using photo-etching technology on the cold and hot sides of the
heat transfer plates, as shown in Figure 2. Each channel consists of an inlet, a straight middle and an
outlet section, all having a half-moon shaped cross section. Two types of heat exchangers were
fabricated with different structures. One (PCHE#1) has three hot-side plates and four cold-side plates,
and the other (PCHE#2) has five hot-side and six cold-side plates, each with the hot and cold-side
plates alternately layered. On the top and bottom of the layered heat transfer plates, extra (end) plates
were bonded in order to increase structural strength. The structure and flow configuration are shown in
Figure 3. The flow configuration was set for a counterflow to obtain a smaller approach temperature.
Once the heat transfer plates were bonded, inlet and outlet ports were attached using electric welding.
Due to a lack of gasket and the close distance between the hot fluid and cold fluid, the manufactured
PCHEs have a high heat transfer rate.

(A)

(B)
Figure 2. Photos of the metal-plates with straight middle sections. (A) Hot-side plate; (B)
Cold-side plate.

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(B)

(C)

Figure 3. The stack layer and the flow pattern in the microchannel printed circuit heat
exchanger (PCHE). (A) PCHE#1 (3 hot/4 cold); (B) PCHE#2 (5 hot/6 cold); (C) Flow
configuration.
Figure 4 shows the microchannel PCHE used, and detailed specifications are listed in Table 1.
One-quarter of the PCHE was cut out in order to confirm the shape of the internal channels and the
bonding condition of heat transfer plates. The cut PCHE and the cross-sectional pictures of channel are
shown in Figure 5. The cross-section shows half-moon shaped channels, characteristic of the micro
photo-etching process employed. The entrance area (Ac) and the effective heat transfer (As) area
were calculated considering the half-moon profile. Furthermore, as shown in the figure, the bonding
conditions of the plates were excellent.

(A)

(B)

Figure 4. The final shape of the microchannel printed circuit heat exchanger (PCHE). (A)
The final shape of the PCHE; (B) Detail design drawing sheet.

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Table 1. Microchannel printed circuit heat exchanger (PCHE) Specifications.

Metal-plate material
Dimensions of PCHE (W L H), mm
Dimensions of plates (W L H), mm
Dimensions of end plates (W L H), mm
Hot side
Number of plates
Cold side
Number of channels per plate
Channel width
Land (solid) width
Channel height

SUS304L
141 40 16
141 40 1
141
3, 5
4, 6
22
800 m
600 m
600 m

Figure 5. Cross-sectional view of a microchannel printed circuit heat exchanger (PCHE)

fabricated through the diffusion-bonding method.
2.2. Experimental Setup
Figure 6 shows the experimental setup. It consists of two sections, one circulating the hot fluid and
the other circulating the cold fluid. In order to maintain constant inlet temperature and flow rate, each
section has a thermostatic bath, a controllable magnetic gear pump, and a volumetric flowmeter.
A filter was installed at the inlet of each flowmeter to remove foreign matter in the fluid and to prevent
fluctuations in, and rusting of, the flow meter. Insulation has been provided all across the sections
in the experimental setup in order to minimize heat loss. Thermocouples, as well as absolute and
differential pressure gauges, were installed at all inlets and outlets. Prior to performing experiments,
each measuring device was calibrated. Thereafter, the data of flow rate, temperature, pressure,
differential pressure etc. were stored on a computer by using a data acquisition unit (DAQ). After the
experimental setup had reached a pre-designated steady-state operating condition, all the measurements
were stored at 5 s intervals.

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(A)

(B)
Figure 6. Schematic diagram and photograph of the experimental setup. (A) Photograph of the
experimental setup; (B) Flow diagram of the experimental setup.
2.3. Experimental Conditions and Results Analysis
Water was used as the hot and cold fluid. The inlet temperatures for the hot fluid were 40 C and 50 C.
The experiment was performed while keeping the cold fluids inlet temperature constant at 20 C. The
hot and cold flow rates were measured in a range of 0.3771.391 L/min, where the flow and pressure
drop were both stable. The Reynolds number was calculated in a range from 100850.
The hydraulic diameter and Reynolds number are calculated using the method suggested by
Cowell [30] as:

=
Re =

(1)
=

(2)

where Ac is the free flow area, As is the total heat transfer area and Lf is the length of the flow stream in
a channel. On the hot side, Ac is 31.7 mm2 and As is 26,037 mm2. On the cold side, Ac is 42.2 mm2 and

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As is 34,716 mm2. Lf is 137 mm and Dh is 0.6685 mm on both sides.

The heat transfer rate in the hot and cold fluids passing through the test section can be obtained
using Equations (3) and (4):
=

(3)

(4)

The heat performance (UA) value can be obtained by using the logarithmic mean temperature
difference (LMTD) and the average heat transfer rate, as represented by Equation (7):

1n

(5)

,
,

+
2

=
=

(6)
(7)

Generally, the overall heat transfer coefficient can be calculated from the sum of the thermal
resistances as in:
1

(8)

where t, k, and Am denotes the gap between the hot and cold side channelswhich is 0.4 mmthe
thermal conductivity of the heat transfer plate is 16.2 W/mK, and the average heat transfer area
respectively. The hot-side heat transfer coefficient, hh and the cold-side heat transfer coefficient,
hc were obtained by using the modified Wilson plot method [31]. The measurement error was
calculated using Equation (9):
(%) =

(9)

Only the results within 7% error boundaries were selected as shown in Figure 7. The total pressure
drop of the microchannel PCHE may be expressed as:
=

1.5
2

+
=

1
2

(10)

where (1/)m is the average density across the flow path and Gp denotes the mass flux at the inlet port.
Note that the effect of hydrostatic pressure is neglected. The pressure drop was the measured sum of
the microchannel, the inlet ports, and the outlet ports [32]. Experimental uncertainty was calculated by
using ASME PEC 19.1 [33] and NIST Technical Note 1297 [34]. The total uncertainty consists of bias
error and precision error as shown in Equation (11). When propagating errors, Equation (12) gives the
uncertainty of the calculated parameters based upon the measured variables:

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=2

(11)

(12)
=1

Figure 7. Heat balance between hot and cold sides.

In Equations (11) and (12), is the total uncertainty, B is Bias error, S is a standard deviation, N is
the number of measurements, and p is the computational variable. The experiments were conducted by
repeating each measurement three times (N = 3). The detailed results for the uncertainty analysis in
this experiment are presented in Table 2.
Table 2. Parameters and estimated uncertainty.
Parameters
Temperature, T
Pressure drop, P
Flow rate of hot side,
Flow rate of cold side,
Averaged heat transfer rate, Qm
Reynolds number of hot side
Reynolds number of cold side
Heat transfer coefficient of hot side
Heat transfer coefficient of cold side
Friction factor, f

Uncertainty (%)
0.6
0.92
1.19
0.94
1.19
3.13
3.29
7.36
7.31
5.8

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3. Experimental Results and Discussion

3.1. Heat Transfer Characteristics
Figures 810 show the heat transfer characteristics of the two types of heat transfer exchangers, i.e.,
PCHE#1 and PCHE#2 in Figure 3, measured for various Reynolds number conditions on the hot and
cold sides. Figure 8A shows the average heat transfer rates measured keeping the same Reynolds
numbers on both sides. Note that the flow rate of the cold fluid is larger than that of the hot fluid to
maintain the same Reynolds number as there is one more plate (channel) on the cold side in the PCHEs
(see Figure 3). Two cases of hot-side inlet temperature, i.e., 40 and 50 C, were measured while
cold-side inlet temperature was fixed at 20 C. The heat transfer rate is larger for PCHE#2 than
PCHE#1 as the same hot-side inlet condition and the influence of hot-side inlet temperature is also
larger for PCHE#2.

(A)

(B)

Figure 8. Average heat transfer rate and the heat performance (UA) with the same
Reynolds number on hot and cold sides. (A) Average heat transfer rate vs. Reynolds number;
(B) UA vs. Reynolds number.
Figure 8B shows the corresponding UA values. The figure shows that the UA increases very slowly
with an increasing Reynolds number and the UA value of PCHE#2 is largerby about 1.8 timesthan
that of PCHE#1, which is expected from Figure 8A. It seems that the influence of the inlet temperature
is minimal as the UA is practically the same for the different inlet conditions considered. In comparison
with PCHE#1, PCHE#2 has more plates, having a larger free flow and heat transfer area. Since
the flow conditions, i.e., Reynolds numbers, are the same, it may be assumed that U is the same in
both heat exchangers. Then, the difference between the two heat exchangers UAs in Figure 8A is
attributable to the difference in heat transfer area.
In order to see the influence of flow direction, PCHE#1 was additionally tested in a parallel
configuration for 40 C hot-side inlet condition. The results were compared with the corresponding
countercurrent results in Figure 9. The average heat transfer rate of countercurrent configuration is
about 6.8% larger than that of parallel flow. The UA of the countercurrent flow is approximately
10%15% larger than parallel flow. In the case of the countercurrent flow, logarithmic mean

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temperature difference is smaller than the parallel flow by ca. 0.31.0 K.

The same heat exchangers were measured again, varying only the hot-side Reynolds number while
fixing the cold-side Reynolds number at 200, 250, and 300. The hot- and cold-side inlet temperatures
were fixed at 40 C and 20 C, respectively. Figure 10 shows the results.
The experiment shows the tendency that the more the Reynolds number of the hot and cold sides
increases, the more the average heat transfer rate and heat transfer performance increases. However, as
the Reynolds number of the hot side is increased, the increase range in heat transfer rate and heat
transfer performance narrows. This narrowing is the change of the hydrodynamic entry region as it
becomes fully developed due to the increase in the mass flow rate of the hot side. Figure 10A shows
that the Reynolds number of the cold side was 200, 250, and 300, and that the average heat transfer
rate in PCHE#2 was 1.5 times more than that of PCHE#1. The heat transfer performance of PCHE#2,
as indicated in Figure 10B, was approximately 1.6 times higher than PCHE#1.

(A)

(B)

Figure 9. Influence of flow configuration (countercurrent vs. parallel). (A) Average heat
transfer rate vs. Reynolds number; (B) Heat performance (UA) vs. Reynolds number.

(A)

(B)

Figure 10. Influence of stacked lamination (PCHE#1 vs. PCHE#2). (A) Average heat
transfer rate vs. Reynolds number; (B) Heat performance (UA) vs. Reynolds number.

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In order to obtain a new heat transfer coefficient from a single-phase experiment, the UA value that
previously represented the heat transfer performance was used to determine the correlation of heat
transfer coefficient in this experiment. The Wilson plot method [35] is known as the method which,
after calculating the overall heat transfer coefficient from a heat exchanger, obtains each heat transfer
coefficient of the hot and cold sides using those values. Currently the modified Wilson plot method,
used in various experimental ranges, is widely used. In this study, the modified Wilson plot method
was used in order to obtain the heat transfer coefficient of the hot and cold sides, respectively. The heat
transfer coefficient can be expressed as Equation (13) for the heat resistance balance of the hot and
cold sides by using Re and Pr of power-law form:
1

where coefficients
analysis [36].

and

Re Pr1/3

Re Pr1/3

Re Pr1/3

(13)

and Re index were calculated using iterative multiple linear-regression

Figure 11. Typical modified Wilson plot results for the calibration of the cold-side heat
transfer coefficient.
Figure 11 shows the results of the heat transfer experiments of the cold side, obtained by using the
modified Wilson plot method. N represents the number of lamination layers which are the cold side.
The convective heat transfer coefficient correlation of the cold side in the Reynolds number range is
the same as Equation (14):
= 0.1706

0.44

Re0.324 Pr1/3

0.14

( /

, 100 < Re < 550

(14)

The heat transfer coefficient of the hot side can be obtained by using the heat transfer coefficient
correlation proposed for the cold side. N indicates the number of lamination layers of the hot side.
Equation (15) expresses the proposed convective heat transfer coefficient correlation:
= 0.1729

0.44
0.324 1/3
Pr
Re

0.14

( /

, 100 < Re < 850

(15)

Figure 12A shows an error range within 7% when comparing the experiments results and
Equation (15). Figure 12B shows the results of comparing the difference between the Nusselt number,
which is non-dimensional form, and the proposed correlation (Equation (15)) by using the calculated

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convective heat transfer coefficient. If these results are represented in the form of a new correlation,
including the variable of the number of lamination layers, it can be expressed as Equation (16):

= 0.7203Re0.1775
Pr1/3

0.14

(16)

The accuracy of the correlation within the range of 7% and the Reynolds number range from
100850 were proposed for the range of this experiment.

(A)

(B)

Figure 12. Comparision of suggested correlations and experimental data for hot-side heat
transfer coefficients. (A) Heat transfer coefficient; (B) Nusselt number.
3.2. Pressure Drop Characteristics
Figure 13 shows the pressure drop according to the change of the Reynolds number and temperature
of the hot and cold sides. As the Reynolds number increases, the figure shows the tendency of the
pressure drop to also increase. The increase of the Reynolds number represents the increase of the
mass flow rate in the microchannel. This increase causes an increase in flow resistance, and as a result,
the pressure drop will also increase. When the temperature of the hot and cold sides are 40 C and 20 C,
respectively, the pressure drop, according to the change of the cold fluids Reynolds number, shows
that the Reynolds number for the hot and cold fluids increases equally as the pressure drop increases.
In the range of this experiment, the pressure drop of the hot side, according to the change of the mass
flow rate of the cold side, is not significantly influenced. If the inlet temperature of the hot side is
increased to 50 C, Figure 14A shows a slight pressure drop. This change results from the influence of
viscosity and density according to the change of the inlet temperature of the hot fluid. As the inlet
temperature increases, density and viscosity are reduced. On the other hand, the UA indicating the heat
transfer performance shows almost the same performance and is not affected by the inlet temperature.

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(A)

(B)

Figure 13. Pressure drop vs. Reynolds number in all experiments. (A) Difference in inlet
temperature; (B) Difference in number of lamination layers.
Figure 14 shows a graph using Equation (10), which is the theoretical equation that represents the
pressure drop. Equation (16) expresses the friction factor fN, which is the result value of the pressure
drop according to Reynolds number. N indicates the number of lamination layers of the hot side. The
total pressure drop was divided by the number of lamination layers. The friction factor correlation is
represented by the function of the Reynolds number, and is as follows:
= 1.3383Re0.5003 , 100 < Re < 850

(17)

The exponent of the Reynolds number was calculated using the least squares method. The accuracy
of the correlation and the experimental results are within 8%, and the coverage of the Reynolds
number is 100850.

Figure 14. Comparison of the friction factor correlation and experimental data for the
microchannel printed circuit heat exchanger (PCHE).

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Figure 15 shows comparison of the proposed non-dimensional form, Colburn j-factor, and friction
factor. The proposed correlation was compared with the Kays and London correlation [37] for the
corrugated surface and offset strip fin configuration, which utilized a Reynolds number range of
4003000. Within the flow direction of these two improved channel configurations, the working fluid
is disturbed, resulting in a higher heat performance than the straight channel configuration. It was
found that the offset-strip-fin configuration had the highest heat performance, followed by the
corrugated-surface configuration. Inversely, the straight microchannel exhibited the lowest friction
factor, followed by the corrugated surface and with the offset strip fin configuration having the highest
friction factor.

Figure 15. Comparison of the proposed friction factor correlation with previous correlations.
4. Conclusions
In this study, the single-phase experiment for the characteristics of the heat transfer and the pressure
drop of the microchannel PCHE was carried out. Based on this single-phase experiment, the following
values and characteristics of the heat transfer coefficient and friction coefficient correlation were proposed.
(1) The average heat transfer rate of the counterflow PCHE is about 6.8, and the UA of the heat
transfer performance is excellent to the extent of approximately 10%15%.
(2) As the Reynolds number of the hot and cold sides increases and the inlet temperature increases,
the average heat transfer rate also increases. This increase was the general performance
characteristic of the heat exchanger according to the increase of the flow rate.
(3) As the Reynolds number of the hot and cold sides increases, the pressure drop increases. If the
inlet temperature of the hot side is constant, the pressure drop according to the change of
Reynolds number of the cold side shows equal results.
(4) The heat transfer performance is not affected by the change in the inlet temperature of the hot
side, but if the inlet temperature is high at the time of the pressure drop, which shows a slight
pressure drop.
(5) The heat transfer coefficient correlations of the hot and cold sides using the modified Wilson
plot method are proposed. The Reynolds number range of these correlations is 100850.

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(6) The friction factor fN was calculated using the pressure drop results. The application scope is the
same as above. It is expected that the experimental results obtained in this study will be usable
as the basis for future performance experimental data.
Acknowledgments
The authors would like to acknowledge the late Dr. Kyu-Jung Lee (Korea University, College of
Mechanical Engineering) for his mentorship and for sharing his expertise in heat transfer.
Author Contributions
The initial research concept and research design was completed by Jang-Won Seo, Yoon-Ho Kim
and Kyu-Jung Lee. Jang-Won Seo conducted background research into previous studies. Yoon-Ho
Kim manufactured the PCHE used in the study. Jang-Won Seo constructed the experimental apparatus
and performed all experiments. Jang-Won Seo and Dongseon Kim undertook data analysis. This
manuscript was primarily written by Jang-Won Seo with Jang-Won Seo and Young-Don Choi
providing assistance. All authors have read and approved the final manuscript.
Nomenclature
Ac
As
B
Cp
Dh
f
G
Gp
H
j
L

Minimum free flow area (mm2)

Total effective heat transfer area (mm2)
Bias error
Specific heat (J/kgK)
Hydraulic diameter (mm)
Friction factor
Core mass velocity (kg/m2s)
Fluid mass velocity in the port (kg/m2s)
Thickness of metal sheet (mm)
Colburn j-factor
Length of metal sheet (mm)

Nu
Pr
Re
UA
h
k
N
P
Q
TLMTD
W

Nusselt number
Prandtl number
Reynolds number
Heat transfer performance (W/K)
Heat transfer coefficient (W/m2K)
Thermal conductivity (W/mK)
Stacked number of metal sheet
Pressure drop (kPa)
Heat transfer rate (W)
Log mean temperature difference (K)
Width of metal sheet (mm)

Fluid density (kg/m3)

Dynamic viscosity (Ns/m2)

Uncertainty

Cold
Inlet
Outlet

h
m

Hot
Mean

Greek Symbols

Subscripts
c
i
o

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Conflicts of Interest
The authors declare no conflict of interest.
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